WO2004114332A2 - Low voltage composite mold - Google Patents
Low voltage composite mold Download PDFInfo
- Publication number
- WO2004114332A2 WO2004114332A2 PCT/US2004/018443 US2004018443W WO2004114332A2 WO 2004114332 A2 WO2004114332 A2 WO 2004114332A2 US 2004018443 W US2004018443 W US 2004018443W WO 2004114332 A2 WO2004114332 A2 WO 2004114332A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- coil
- transformer
- composite material
- inner layer
- outer layer
- Prior art date
Links
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/125—Other insulating structures; Insulating between coil and core, between different winding sections, around the coil
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/061—Winding flat conductive wires or sheets
- H01F41/063—Winding flat conductive wires or sheets with insulation
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/098—Mandrels; Formers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/32—Insulating of coils, windings, or parts thereof
- H01F27/322—Insulating of coils, windings, or parts thereof the insulation forming channels for circulation of the fluid
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/127—Encapsulating or impregnating
Definitions
- This invention generally relates to transformer coils. More particularly, the present invention provides a method of producing a encapsulated transformer coil with composite inner and outer layers.
- a transformer coil is manufactured by forming an inner layer by wrapping a sheet of composite material over a plurality of annular shaped support plates. A coil is wound around the inner layer. An outer layer is formed by wrapping a sheet of composite material over the coil. A coil assembly is formed by mechanically attaching the outer layer to the coil, and a base is attached to the coil assembly. A seal is provided between the base and the coil assembly to prevent epoxy leaks during the encapsulation process. The coil assembly is filled with epoxy to encapsulate the coil.
- At least the inner layer becomes a part of the transformer coil.
- a transformer coil is produced having an inner layer, a plurality of coil windings, an outer layer, and an epoxy material that encapsulates the coil windings and forms a first bond between the coil windings and the inner layer and forms a second bond between the coil windings and the outer layer.
- FIG. 1 is a perspective view illustrating the winding of composite material onto a mandrel for use in manufacturing a transformer coil in accordance with the method of the present invention
- FIG. 2 is a perspective view illustrating the step of winding insulating tape and conductor onto the inner layer to produce the coil of the transformer;
- FIG. 3 is a perspective view showing the coil, wound on the inner layer and an outer layer applied over the coil with cooling duct bars inserted between layers of the coil to produce a manufactured coil assembly;
- FIG. 4 is a perspective view of the manufactured coil assembly of FIG. 3 removed from the winding machine and placed in upright position on a molding base ready for epoxy encapsulation;
- FIG. 5 is a perspective view illustrating the coil and mold assembly after encapsulation of the coil and removal of the cooling duct bars of FIG. 4.
- FIG. 1 depicts a coil winding machine 10 having a conventional square mandrel shaft 12.
- Inner support plates 14 are applied to the mandrel shaft 12.
- the size and shape of the inner support plates 14 establish the size and shape of the finished coil.
- the inner support plates 14 shown in FIG. 1 are elliptical or oval in shape and may be used to produce a coil having an oval configuration.
- the inner support plates 14 may be fabricated from any suitable material, such as 11 gauge steel.
- the number and arrangement of the inner support plates depends for the most part on the size of the transformer.
- FIG. 1 shows four inner support plates 14 that are equally spaced on the square mandrel shaft 12.
- Spacer tubes may be mounted on the mandrel 12 between the inner support plates 14 to maintain the spacing between the inner support plates 14.
- Various lengths of spacer tubes may be used to accommodate various coil axial lengths.
- Lead support plates may be provided to hold the start lead in position during the winding process. The lead support plates may be positioned near the ends of the mandrel 12 and keep the lead from sliding around the mold due to the tension of the winding machine.
- a sheet of composite material 16 is wrapped over the inner support plates 14.
- the composite material 16 is mechanically attached to the inner support plates 14 by a slot, not shown, in the support plates. This locks the sheet of composite material 16 into position so that the sheet can be tightly wrapped around the inner support plates 14, thus eliminating any material slippage during the wrapping process.
- the composite material 16 is applied continuously in several overlapping layers.
- the composite material is preferably non-conductive and flexible. Suitable materials include fiberglass, mylar, carbon fiber, and plastics.
- the sheet of composite material 16 forms the inner layer 20 of the transformer coil and serves as the mandrel base for the coil winding process.
- the wrapped sheet of composite material 16 is held or secured in place with non- adhesive glass tape.
- a plastic tape, for example Mylar tape, is applied over the entire length of the inner layer 20.
- the Mylar tape seals the inner layer 20 for the subsequent epoxy encapsulation process.
- the coil is wound on the inner mold. As shown in FIG. 2, the coil is wound using alternate layers of copper conductor 24 and insulating tape 26 on the conventional winding machine 10. As shown in FIG. 3, cooling duct bars 28 are inserted during winding between every other layer of conductor to provide cooling ducts in the completed transformer.
- the cooling duct bars 28 are preferably coated with a lubricant, such as silicone, prior to being inserted between the coil layers to aid in their later removal from the encapsulated transformer coil.
- other methods of providing cooling ducts may be used, such as those described in commonly assigned U.S. Patent Application No. 10/026,199.
- an outer layer 34 is wrapped around the coil windings.
- the outer layer 34 is constructed of the same composite material as used in making the inner mold 20.
- a sheet of composite material is applied continuously in several overlapping layers, which are mechanically attached to the coil windings 30 with glass adhesive tape to hold the sheet in its starting position.
- non-adhesive glass tape 32 is spirally wrapped over the outer layer 34 to secure it in position.
- the outer layer 34 is secured by banding the mold with banding strip 36 in several locations, as shown in FIG. 3.
- the wound coil and mold assembly 38 is removed from the winding machine 10 and uprighted for mounting and attachment to a molding base 40, as shown in FIG. 4.
- a mechanical arrangement, not shown, preferably including a threaded tie rod is provided for forcing the coil and mold assembly 38 downwardly toward the molding base 40 to compress a silicone gasket, not shown, against the molding base 40, thereby preventing epoxy leaks during the encapsulation process.
- the encapsulation process is preferably a conventional vacuum encapsulation process used in manufacturing transformer coils.
- the cooling duct bars 28, FIG. 4 are removed as shown in FIG. 5.
- the banding straps 36 holding the outer mold 34 are removed.
- the mechanical structure securing the mold and coil assembly 38 to the molding base 40 are removed, and the encapsulated coil 30 is removed from the molding base 40.
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA2527768A CA2527768C (en) | 2003-06-11 | 2004-06-10 | Low voltage composite mold |
EP04754901A EP1631972A4 (en) | 2003-06-11 | 2004-06-10 | Low voltage composite mold |
BRPI0411251-2A BRPI0411251A (en) | 2003-06-11 | 2004-06-10 | low voltage composite mold |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/459,055 | 2003-06-11 | ||
US10/459,055 US6930579B2 (en) | 2003-06-11 | 2003-06-11 | Low voltage composite mold |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2004114332A2 true WO2004114332A2 (en) | 2004-12-29 |
WO2004114332A3 WO2004114332A3 (en) | 2005-10-20 |
Family
ID=33510720
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2004/018443 WO2004114332A2 (en) | 2003-06-11 | 2004-06-10 | Low voltage composite mold |
Country Status (6)
Country | Link |
---|---|
US (1) | US6930579B2 (en) |
EP (1) | EP1631972A4 (en) |
CN (1) | CN100524550C (en) |
BR (1) | BRPI0411251A (en) |
CA (1) | CA2527768C (en) |
WO (1) | WO2004114332A2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102267210A (en) * | 2011-08-01 | 2011-12-07 | 保定天威集团有限公司 | Method for casting transformer coil and special mold |
Families Citing this family (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN1741210B (en) * | 2005-09-05 | 2010-05-26 | 韶关市韶特电气有限公司 | Dry type electric transformer teeming epoxy resin coil non-cutting technology |
CN101802944B (en) * | 2007-08-09 | 2013-03-27 | Abb技术有限公司 | Coil bus for a transformer and a method of manufacturing the same |
CN102696081B (en) * | 2009-09-11 | 2016-02-24 | Abb研究有限公司 | Comprise the transformer of heat pipe |
EP2556521B1 (en) | 2010-04-07 | 2018-05-30 | ABB Schweiz AG | Outdoor dry-type transformer |
US9111677B2 (en) * | 2010-04-07 | 2015-08-18 | Abb Technology Ag | Method of manufacturing a dry-type open wound transformer having disc windings |
PL2528075T3 (en) * | 2011-05-25 | 2014-04-30 | Abb Schweiz Ag | Coiling method, coiling device and transformer coil |
US9257229B2 (en) | 2011-09-13 | 2016-02-09 | Abb Technology Ag | Cast split low voltage coil with integrated cooling duct placement after winding process |
WO2013063242A1 (en) | 2011-10-28 | 2013-05-02 | Abb Technology Ag | Integral mold for a transformer having a non-linear core |
CN103177868A (en) * | 2013-04-09 | 2013-06-26 | 国家电网公司 | Combined sleeving table of bulging-die-type transformer coil |
US11242991B2 (en) * | 2019-05-15 | 2022-02-08 | Raytheon Technologies Corporation | CMC component arrangement and method of manufacture |
CN112117125B (en) * | 2020-08-27 | 2022-04-08 | 江门市蓬江区恒驰新材料有限公司 | Automatic change coil and twine sticky tape equipment |
Family Cites Families (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4095206A (en) * | 1975-02-10 | 1978-06-13 | Victor Company Of Japan, Limited | Encapsulated transformer assembly |
JPS5463222A (en) * | 1977-10-28 | 1979-05-22 | Mitsubishi Electric Corp | Manufacture of mold coil |
JPS5763816A (en) * | 1980-10-06 | 1982-04-17 | Hitachi Ltd | Molded transformer coil |
US4337219A (en) | 1980-12-09 | 1982-06-29 | Square D Company | Method of encapsulating electrical coils |
JPS57121207A (en) * | 1981-01-21 | 1982-07-28 | Hitachi Ltd | Manufacture of plastic molded coil |
JPS57141902A (en) * | 1981-02-25 | 1982-09-02 | Mitsubishi Electric Corp | Insulating coil |
DE3234098A1 (en) | 1982-09-14 | 1984-03-15 | Transformatoren Union Ag, 7000 Stuttgart | METHOD FOR PRODUCING WINDINGS EMBEDDED IN CASTING RESIN FOR TRANSFORMERS |
JPS6132411A (en) * | 1984-07-23 | 1986-02-15 | Rishiyou Kogyo Kk | Manufacture of dry type transformer |
JPH0690983B2 (en) * | 1984-10-22 | 1994-11-14 | 株式会社日立製作所 | Resin molded coil |
US5036580A (en) | 1990-03-14 | 1991-08-06 | E. I. Du Pont De Nemours And Company | Process for manufacturing a polymeric encapsulated transformer |
US5589808A (en) | 1993-07-28 | 1996-12-31 | Cooper Industries, Inc. | Encapsulated transformer |
US6223421B1 (en) * | 1999-09-27 | 2001-05-01 | Abb Power T&D Company Inc. | Method of manufacturing a transformer coil with a disposable mandrel and mold |
US6221297B1 (en) * | 1999-09-27 | 2001-04-24 | Abb Power T&D Company Inc. | Method of manufacturing a transformer coil with a disposable wrap and band mold and integrated winding mandrel |
US20020101315A1 (en) * | 2001-01-31 | 2002-08-01 | Colin Hamer | Ignition coil with primary winding release |
US6624734B2 (en) * | 2001-09-21 | 2003-09-23 | Abb Technology Ag | DC voltage/current heating/gelling/curing of resin encapsulated distribution transformer coils |
-
2003
- 2003-06-11 US US10/459,055 patent/US6930579B2/en not_active Expired - Lifetime
-
2004
- 2004-06-10 CN CNB2004800162000A patent/CN100524550C/en not_active Expired - Fee Related
- 2004-06-10 CA CA2527768A patent/CA2527768C/en not_active Expired - Fee Related
- 2004-06-10 EP EP04754901A patent/EP1631972A4/en not_active Withdrawn
- 2004-06-10 WO PCT/US2004/018443 patent/WO2004114332A2/en active Search and Examination
- 2004-06-10 BR BRPI0411251-2A patent/BRPI0411251A/en not_active IP Right Cessation
Non-Patent Citations (1)
Title |
---|
See references of EP1631972A4 * |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102267210A (en) * | 2011-08-01 | 2011-12-07 | 保定天威集团有限公司 | Method for casting transformer coil and special mold |
Also Published As
Publication number | Publication date |
---|---|
CA2527768C (en) | 2013-10-29 |
US20040251998A1 (en) | 2004-12-16 |
CA2527768A1 (en) | 2004-12-29 |
BRPI0411251A (en) | 2006-07-25 |
US6930579B2 (en) | 2005-08-16 |
CN1806303A (en) | 2006-07-19 |
CN100524550C (en) | 2009-08-05 |
EP1631972A4 (en) | 2011-04-06 |
EP1631972A2 (en) | 2006-03-08 |
WO2004114332A3 (en) | 2005-10-20 |
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